Adhesive-Sealed Corner Gap Encapsulation for Appliance Door Panels
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Solution Overview
Problem
Existing cabinet structures for appliances face challenges in effectively sealing gaps at the corners of door panels, which can lead to insulation leakage and reduced efficiency.
Innovation Solution
A method involving folding metallic sheets to create side edges with defined gaps, securing interior blocks to form adhesive cavities, and applying a fast-curing adhesive within these cavities to create a solid sealing member that hermetically seals the gaps, with removable exterior blocks minimizing seam appearance and allowing for vacuum insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding or fastening methods are used to seal gaps at corner joints, then structural strength is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces traditional mechanical sealing methods (welding, fastening) with a chemical bonding system. Adhesive is applied to the corner joints and cured to form a sealing member that hermetically seals the gaps between adjacent side edges, eliminating the need for complex mechanical fastening or welding operations
Solution Approach 2:
The patent applies adhesive to the corner joints before final assembly and curing. The adhesive is positioned in advance within the gap between adjacent side edges, and after curing, forms a sealing member that permanently seals the joint. This preliminary application simplifies the overall manufacturing process by combining sealing and assembly steps
2Reliability
If traditional sealing methods are used, then gap sealing is achieved, but insulation efficiency deteriorates due to seam appearance and potential leakage paths
Solution Approach 1:
The patent extracts the sealing function from traditional mechanical fasteners and creates a dedicated sealing member through adhesive curing. This sealing member hermetically seals the gap between adjacent side edges, eliminating potential leakage paths that would compromise insulation efficiency
Solution Approach 2:
The cured adhesive forms a flexible yet hermetic sealing member that conforms to the gap between adjacent side edges. This sealing member provides reliable sealing without creating visible seams or compromising the insulating cavity integrity
3Ease of manufacture
If adhesive is applied without containment structures, then application simplicity is improved, but adhesive leakage and imprecise sealing occur
Solution Approach 1:
The patent introduces adhesive cavities as intermediary containment structures. These cavities are formed by blocking portions of the corner joints and provide a defined space for adhesive application. The cavities prevent adhesive leakage while ensuring precise positioning of the sealing material at the gap between adjacent side edges
Solution Approach 2:
The patent creates localized adhesive cavities at specific corner joint locations where sealing is required. Each cavity is precisely positioned to contain adhesive at the gap between adjacent side edges, providing localized precision sealing without affecting other areas of the structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method provides a hermetic seal at the gaps, preventing gas and vapor permeation, and allows for the creation of vacuum-insulated structures without the need for welding or additional fasteners, enhancing the insulation efficiency and aesthetic appeal of appliance door panels.
Implementation Method 1
The adhesive is cured to form a solid sealing member within each adhesive cavity that adheres the respective interior block to the interior surface of the structural outer panel
Implementation Method 2
An adhesive is disposed within each adhesive cavity, wherein the adhesive substantially fills each gap and is contained in the adhesive cavities by the interior and exterior blocks
Implementation Method 3
a back panel is disposed onto the side edges of the structural outer panel, wherein the back panel, structural outer panel, and the solid sealing member define an insulating cavity therein
Data Source
AI summary
A method of forming an insulated door panel includes folding side flanges of a metallic sheet to define side edges of a structural outer panel that extend from a front panel. A gap is defined between each set of adjacent side edges. Interior blocks are secured to an interior of the structural outer panel proximate each gap to define adhesive cavities. Exterior blocks are positioned at an exterior surface of the structural outer panel at each gap to further define the adhesive cavities. An adhesive is disposed within each adhesive cavity and is contained therein by the interior and exterior blocks. The adhesive is cured to a solid sealing member that adheres the interior blocks to the interior surface of the structural outer panel to form a sealed structural panel. The exterior blocks are removed and each solid sealing member defines a hermetic seal at each gap.